REPLICAST 112 Versatile Fast-Setting Tooling System
DESCRIPTION
REPLICAST
112 is a low viscosity fast-setting polyurethane casting system that is
useful for a variety of casting applications. Its low mixed viscosity
makes it ideal for casting prototype or production parts where very fine
detail must be duplicated. It is also well suited for potting and
encapsulating uses, as well as general tooling and fixtures.
REPLICAST 112 offers the following benefits:
-Non-settling – eliminates lengthy remixing of hard packed fillers
-Easy mix ratio for fast measuring
-Very low shrinkage
-Cured material is very easy to machine
-Fast demold time – quick, reliable tool production
-Safe, non-toxic materials for safety in the workplace
Filler PA0738 is a white, high purity alumina material in a fine powder form that is very easy to add to REPLICAST 112. The particle size and shape of PA0738 gives it a very free-flowing consistency, and also allows high loading of the REPLICAST 112, while maintaining a good pouring viscosity. The cured material is a medium tan color. Castings made with REPLICAST 112 and filler have very little shrinkage and are quite easy to machine.
HANDLING & CURING
REPLICAST 112 has the ability to tailor the mixture to suit the
application. Lower levels of filler maintain a relatively low mixed
viscosity for easy filling of thin section molds. Higher filler loading
minimizes cured shrinkage in larger castings. By varying the amount of
bulk filler used, a wide variety of different requirements can be met.
REPLICAST 112 allows greater versatility and eliminates the time and
effort of redispersing settled filler.
Recommended filler loading levels range from 88 Parts Resin : 100
Parts Hardener : 100 Parts Filler, up to 88 Parts Resin : 100 Parts
Hardener : 300 Parts Filler, by weight. Ratios under 100 Parts Filler by
weight may have excessive shrinkage if used to make very large
castings. Ratios over 300 Parts Filler by weight will usually be too
thick to pour easily. Experimentation using these guidelines is
suggested to determine the best ratio for the particular job type. The
working time of REPLICAST 112 was developed for the unfilled material.
Therefore, when bulk fillers are used, the material is slowed down,
allowing a longer working time to add the fillers and make the casting.
This aids greatly in avoiding trapped air caused by trying to mix
fillers into an exceptionally fast gelling system.
TYPICAL MECHANICAL PROPERTIES
| REPLICAST 112 | REPLICAST 112 with Filler | ASTM Method | ||
| (No Filler Added) | Ratio 1 | Ratio 2 | ||
| Mix Ratio, by Weight (Resin : Hardener : Filler) | 88 A : 100 B | 88 : 100 : 200 | 88 : 100 : 300 | PTM&W |
| Gel Time, @ 77°F | 3 – 4 min. | 11 min. | 12 min. | D2471 |
| Cured Hardness | 75 Shore D | 76 Shore D | 77 Shore D | D2240 |
| Shrinkage, in./in., Mold #2, Volume: .344 gal. | .002 | .0003 | .0002 | D2566 |
| Specific Gravity, grams, cc | 1.07 | 1.48 | 1.51 | D1475 |
| Tensile Strength, psi | 4900 psi | 3000 psi | 2900 psi | D638 |
| Elongation @ Break, % | 30 % | .95 % | .63 % | D638 |
| Flexural Strength, psi | 6000 psi | 7160 psi | 7610 psi | D790 |
| Bashore Rebound | 37 % | 18 % | 13 % | D2632 |
PACKAGING INFORMATION
| REPLICAST 112 | Gallon Kit | Pail Kit | |
| REPLICAST 112 Part A | 8 lb. | 40 lb. | |
| REPLICAST 112 Part B | 9 lb. | 45 lb. | |
| Kit | 17 lb. | 85 lb. | |
| PA0738 Filler – Bulk Packaging | 5-Gallon Pail | Fiber Drum (Special Order) | |
| PA0738 Filler | 50 lb. | 225 lb. | |
| REPLICAST 112 Case Pack | |||
| Case Contents | Package | Net Weight | Net Volume |
| REPLICAST 112 | 1 Gallon Kit | 17 lb. | 1.91 Gallons |
| PA0738 Filler | 2 Gallons PA0738 | 10.5 lb. ea. | 1.88 Gallons |
| Case | 38 lb. | 3.79 Gallons |
SAFETY & HANDLING
PTM&W epoxy products are made from raw materials carefully chosen to minimize or even eliminate toxic chemicals, and therefore offer the user high performance products with minimum hazard potential when properly used. Generally, the PTM&W epoxy resins and hardeners will present no handling problems if users exercise care to protect the skin and eyes, and if good ventilation is provided in the work areas. However, all epoxy resins and hardeners can be irritating to the skin, and prolonged contact may result in sensitization; and breathing of mist or vapors may cause allergenic respiratory reactions, especially in highly sensitive individuals. As such, avoid contact with eyes and skin, and avoid breathing vapors. Wear protective rubber apron, clothing, gloves, face shield or other items are required to prevent contact with the skin. In case of skin contact, immediately wash with soap and water, followed by a rinse of the area with vinegar, and then a further wash with soap and water. The vinegar will neutralize the hardener and lessen the chances of long term effects. Use goggles, a face shield, safety glasses or other items as required to prevent contact with the eyes. If material gets into the eyes, immediately flush with water for at least 15 minutes and call a physician. Generally, keep the work area as uncluttered and clean as possible, and clean up any minor spills immediately to prevent accidental skin contact at a later time. Keep tools clean and properly stored. Dispose of trash and empty containers properly. Do not use any of these types of products until Material Safety Data Sheets have been read and understood.